Relay Contact Spring With Magnetic Repulsion Force Intensification
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Solution Overview
Problem
Existing relays lack sufficient contact force in the closed relay position, which affects the reliability of circuit closure and interruption.
Innovation Solution
Designing the contact element as a contact spring with a second continuous line running parallel to its surface, utilizing a magnetic drive with a reversible coil and armature to enhance contact force through magnetic repulsion, and using a common magnetic drive for multiple relays to achieve simultaneous deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a bridge element is used to close or interrupt the circuit, then the relay structure is simple, but the contact force in the closed relay position is insufficient
Solution Approach 1:
The patent replaces the purely mechanical bridge element actuation with an electromagnetic drive system. A magnetic coil generates a magnetic field that acts on a magnetic contact element, providing additional magnetic force to enhance the contact force when the relay is closed. This substitution of mechanical actuation with electromagnetic actuation resolves the contradiction by introducing a new force mechanism without fundamentally changing the bridge element structure.
Solution Approach 2:
The contact element is designed as a magnetic contact element that combines mechanical bridge element properties with magnetic material properties. This composite approach allows the same component to respond to both mechanical actuation and magnetic field forces, thereby increasing the contact force in the closed position while maintaining the simplicity of the bridge element structure.
2Force
If the second line is positioned closer to the contact spring to increase magnetic repulsion force, then the magnetic contact force increases, but the risk of electrical breakdown between the lines increases
Solution Approach 1:
The patent introduces a non-conductive coating on the second line that acts as an intermediary layer between the conductive second line and the contact spring. This coating allows the second line to be positioned close to the contact spring for strong magnetic interaction while preventing direct electrical contact and breakdown. The coating mediates between the conflicting requirements of proximity for magnetic force and separation for electrical insulation.
Solution Approach 2:
The patent changes the electrical parameter of the second line by applying a non-conductive coating, which alters its surface properties from conductive to insulating. This parameter change allows the system to achieve close proximity for magnetic force generation while maintaining electrical safety, effectively resolving the contradiction between magnetic force enhancement and breakdown risk reduction.
3Adaptability or versatility
If individual drives are used for each relay, then each relay can be actuated independently, but the device complexity and space requirements increase
Solution Approach 1:
The patent merges multiple individual drive functions into a single common magnetic drive unit that can actuate multiple relays simultaneously. The magnetic field generated by this common drive affects all magnetic contact elements in the relay arrangement, allowing synchronized operation of multiple relays with a single drive mechanism. This merging approach reduces device complexity and space requirements while maintaining the ability to actuate relays independently when needed.
Solution Approach 2:
The common magnetic drive is designed with universal functionality to actuate multiple different relays within the same relay arrangement. A single drive unit serves multiple purposes by generating a magnetic field that can influence all magnetic contact elements, thereby reducing the overall number of drive components needed while maintaining operational flexibility for independent or simultaneous relay actuation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Increases contact force in the closed position, improves reliability by using magnetic repulsion forces proportional to current amplitude and distance, and allows for efficient switching in relay arrangements, particularly in electricity meters.
Implementation Method 1
the contact force with which the contact spring is in contact with the associated relay contact is supported by the magnetic repulsion force exerted by the magnetic field of the current-carrying continuous line on the contact spring, which is current-carrying in the opposite direction
Implementation Method 2
a magnetic drive with a magnetic coil that can be reversed in polarity, an armature with a permanent magnet
Data Source
Figure 1
Figure 2
AI summary
The relay (2) has a dual line (4) guided through a relay housing, and a line (6) of a double line comprising a movable contact spring (10). The contact spring closes an electric circuit of the line (6) in a relay position and is disconnected in another relay position. Another line (7) is formed in an end-to-end manner and runs parallel to the contact spring and before a spring surface (16). The two lines (6, 7) are formed as flat lines, where the lines are turned towards its edges outside an area of the contact spring.